USPTO Patents Application 10092481

Attorney Docket No. 25791.85 PATENT

Claims

What is claimed is:

^r- — An apparatus for -couplfng a tuoular member to a preexisting structure,
comprising: /
a first support member including a first fluid passage; /
a manifold coupled to the support member including: /

a second fluid passage coupled to the first fluid passage including a throat

passage adapted to receive a plug;/
a third fluid passage coupled to the second fluid passage; and
a fourth fluid passage coupled to the'second fluid passage;
a second support member coupled to the manifold including a fifth fluid passage

coupled to the second fluid passage;
an expansion cone coupled^ the/second support member;
a tubular member coupled Ao ra/fji^t support member including one or more

sealing members pcsifioned on an exterior surface;
a first interior chamber defined by the portion of the tubular member above the

manifold, the fipst interior chamber coupled to the fourth fluid passage;
a second interior chamber defined by the portion of the tubular member between
the manifold and the expansion cone, the second interior chamber
coupled to the third fluid passage;
a third intenor chamber defined by the portion of the tubular member below the
expansion cone, the third interior chamber coupled to the fifth fluid
/ passage; and
a^oe coupled to the tubular member including:
/ a throat passage coupled to the third interior chamber adapted to receive
/ a wiper dart; and
' a sixth fluid passagecojjpJedJojD£Lil^ 1

<2, AjrLetho?~oTTcetfptirtg-^^ to a pr oo x ic t iflg structu TeTcomprising:

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H^Qsitio ninga support mem ber, an ex p ansion cone, and a tubular member within — fc

a preexisting structure; /
injecting a first quantity of a fluid iprnaterial into the preexisting structure below

the expansion cone; anjj
injecting a second quantity pft a fluidic material into the preexisting structure

above the expansion cone.

A i i d&fraratus. comprising:

a preexisting structure; and

an expanded tubular member coupled to the preexisting structure; /
wherein the expanded tubular member is coupled to the preexteiifig structure by
a process comprising: X
positioning a tubular support member defining ^internal longitudinal

passage, an expansion cone, and the^ubular member within the

preexisting structure; /
injecting a first fluidic material through/fhe internal passage of the tubular

support member into the preexisting structure below the expansion

cone; and /
injecting a second fluidic rrajterial through the internal passage of the

tubular support mepmerinto the preexisting structure above the

expansion cone/

An apparatus for coupNpfg two elements, comprising:
a support member including one or more support member slots;
a tubular membei/including one or more tubular member slots; and
a coupling for removably coupling the tubular member to the support member,
including:

^coupling body movably coupled to the support member;
/one or more coupling arms extending from the coupling body; and

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coupling elements extending from correspon^ing^oupling arms adapted
to mate with correspond]^ member and tubular member

slots.

A method of coupling a first met
forming a first set of coupling
forming a second set of coupl
aligning the first and second
inserting coupling eleme

'a second member, comprising:
the fira member;

the second member;

upling slots; and
ach of the pairs of coupling slots.

^ An apparatus for controlling the flow of fluidic m aterials within a housing,
comprising: )
a first passage within the housing; S
a throat passage within the housing fluidicly coupled to^re first passage adapted

to receive a plug; /
a second passage within the housing fluidiclvpdupled to the throat passage;
a third passage within the housing fluidicly / 6oupled to the first passage;
one or more valve chambers within ^housing fluidicly coupled to the third

passage including m^vea^le valve elements;
a fourth passage within thfc Naming fluidicly coupled to the valve chambers and

a region outside o^ne housing;
a fifth passage within/the housing fluidicly coupled to the second passage and

controllably^coupled to the valve chambers by corresponding valve

element^; and

a sixth passage within the housing fluidicly coupled to the second passage and
tKe valve chambers.

7. A^method of controlling the flow of fluidic materials within a housing including an

inlet^assage and an outlet passage^xompfism^

injectingJlukl^^ into the inlet passage;

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blocking the inletpassage; and

opening the outlet passaged ^ ^ —

8. An apparatus, comprising: /
a first tubular member; /

a second tubular member positioned within and coupled to the firsj/ttlbular

member; /
a first annular chamber defined by the space between the/first and second

tubular members; /
an annular piston movably coupled to the second ttfoular member and positioned

within the first annular chamber; /
an annular sleeve coupled to the annular piston and positioned within the first

annular chamber; /
a third annular member coupled to the^second annular member and positioned

within and movably couptecLto the annular sleeve;
a second annular chamber defflnedby the space between the annular piston, the

third annular member Jne second tubular member, and the annular

sleeve; /
an inlet passage fluidiclyxoupled to the first annular chamber; and
an outlet passage flujdicly coupled to the second annular chamber.

9. A method of applying an axial force to a first piston positioned within a first piston
chamber, comprising/

applying an/axial force to the first piston using a second piston positioned within
th£ first piston chamber.

10. An apparatus for radially expanding a tubular member, comprising:
a/support member;

^/ 3 tubulaniiem^ QnupipH tn thp sjj^gort member;

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a mandrel movably coupled toth^sui

,the

tubular member;

an annular expansion cone coupled to the mandrel and movably copied to the

tubular member for radially expanding the tubular member; and
a lubrication assembly coupled to the mandrel for supplyincj/a lubricant to the
annular expansion cone, including:
a sealing member coupled to the annular member;
a body of lubricant positioned in an annular chamber defined by the space
between the sealing member, j^e annular member, and the tubular
member; and

a lubrication supply passage flufdicly coupled to the body of lubricant and
the annular expansiqpr cone for supplying a lubricant to the annular
expansion cone.

11. A method of operating aV^pparatus for radially expanding a tubular member

including an expansion cone, comprising:

lubricating the interface between the expansion cone and the tubular member;
centrally positioning the expansion cone within the tubular member; and
applying a substantially constant axial force to the tubular member prior to a
beginning of a radial expansion process.

12. An apparatus, comprising:
a support member;

a tuoular member coupled to the support member;

annular expansion cone movably coupled to the support member and the
tubular member and positioned within the tubular member for radially
expan^ing-theiubular nTembe^^--ami
a f^&to^d assembly for applying an axial force to the annular expansion cone,
including:

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a compressed spring coupled to the support member for applying the axial

— foimlQ-tbe-aftm^ and

a spacer coupled to the support member for controlling the amount of
spring compression.

13. An apparatus for coupling a tubular member to a preexisting s^ucture,
comprising:

a support member;

a manifold coupled to the support member for controlling the flow of fluidic
materials within the apparatus;
|^ a radial expansion assembly movably coupled to/he support member for radially

(5 expanding the tubular member; and

jjj a coupling assembly for removably coupling/fhe tubular member to the support

m

member.

14. An apparatus for coupling a tubujar r^mber to a preexisting structure,
vd comprising:

S3 ,
*y an annular support member incliiding a first passage;

hi a manifold coupled to the annular support member, including:

\u /

a throat passage fluijilcly coupled to the first passage adapted to receive a
fluid plug;

a second passaofe fluidicly coupled to the throat passage;
a third passages fluidicly coupled to the first passage;
a fourth passage fluidicly coupled to the third passage;
one or more valve chambers fluidicly coupled to the fourth passage

including corresponding movable valve elements;
one 9/ more fifth passages fluidicly coupled to the second passage and
controllably couBled-to^rresponding valve chambers by
coiresptJnding movable valve elements;

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one or more sixth passagesjludic^ outside of the

__________---HTiat^ to corresponding valve chambers;

one or more seventh passages fluidicly coupled tc/ corresponding valve

chambers and the second passage; ancK
one or more force multiplier supply passages fluidicly coupled to the fourth
passage; /
a force multiplier assembly coupled to the annular support member, including:
a force multiplier tubular member coupled to the manifold;
an annular force multiplier pistor/chamber defined by the space between
the annular support member and the force multiplier tubular
member and fluidiclyxoupled to the force multiplier supply
passages; /
an annular force multiplier piston positioned in the annular force multiplier
piston chambj^and movably coupled to the annular support

member; u \

a force multiplier/sleeve coupled to the annular force multiplier piston;
a force multiplier sleeve sealing member coupled to the annular support
memper and movably coupled to the force multiplier sleeve for
sealing the interface between the force multiplier sleeve and the
arinular support member;
an annular force multiplier exhaust chamber defined by the space
/ between the annular force multiplier piston, the force multiplier
/ sleeve, and the force multiplier sleeve sealing member; and
ar force multiplier exhaust passage fluidicly coupled to the annular force
/ multiplier exhaust chamber and the interior of the annular support
/ member;
an/expandable tubular member;

a radial expansion assemfely-mevah^^ to the annular support member,
' includingr"**"^

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an annu l a rrrrgngreTpositioned within the an/iular force multiplier piston

chamber;

an annular expansion cone coupled to^he annular mandrel and movably

coupled to the expandable Uroular member;
a lubrication assembly coupled to the annular mandrel for supplying
lubrication to the interface between the annular expansion cone
and the expandable fibular member;
a centralizer coupled to the annular mandrel for centering the annular

expansion cone>within the expandable tubular member; and
a preload assembly movably coupled to the annular support member for
applying an/9xial force to the annular mandrel; and
a coupling assembly counted to the annular support member and releasably
coupled to the Expandable tubular member, including:
a tubular coupling member coupled to the expandable tubular member

including one or more tubular coupling member slots;
an annul/r support member coupling interface coupled to the annular
pport member including one or more annular support member
coupling interface slots; and
a coupling device for releasably coupling the tubular coupling member to
the annular support member coupling interface, including:
a coupling device body movably coupled to the annular support
member;

one or more resilient coupling device arms extending from the

coupling device body; and
one or morexou p li ng device uoup l iny e lements-extending from
corresponding coupling device arms adapted to removably
mate with corresponding tubular coupling member and
annular support member coupling slots.

r^-ST^-'ATTTelF^^ srttrbular member to a pre-existingstiuctuie, conipiisiny-

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^positieftii iy an e x p a nsion cone gmcnfie tubular member within the preexisting

structure using a support rpfember;
displacing the expansion cone /elative to the tubular member in the axial

direction; and /
decoupling the support mernber from the tubular member.

16. yAp nppnrntir., comprising: " J

a preexisting structure; and /

a radially expanded tubular member coupled to the preexisting structure by a
process comprising:

positioning an expansior^e^ne^nd the tubular member within the
preexisting stptf&ttrre using a support member;

displacing the expansion cone relative to the tubular member in the axial
direction; and

deco^gjjngjb&^ upport mombor from -thgjubular member.

TT A meftfPd of muplihy a Yukxi\a^mGXX± &r tn a prePYisf ing StOiCtlUB, comprteirfg :
coupling the tubular member and an annular expansion cone for eng^lng the

tubular member to a tubular support member defining anjfrfernal

longitudinal passage;
positioning the tubular member and the annular expapslon cone within the

preexisting structure using the tubular support member;
injecting a fluidic material through the intepnf^l passage of the tubular support

member into an annular chamber above the annular expansion cone to

displace the annular expafision cone downwardly relative to the tubular

member to radiall^xpand and plastically deform the tubular member;
exhausting fluidic materials out of an annular chamber within the tubular member

belo ^h^annu lar exjjayjon ^^nf^# tfft *^h^n^ infernal paccarp nf th^

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— tuEotarsuppsji^^ displace djayJhe-^ d i sp l cr cemjBrt

of the annular expansion cone; and /
decoupling the tubular support member from the tubular member. /

18. The method of claim 17, wherein coupling the tubular member to the4ubular
support member comprises: /

the tubular support member releasably engaging the tubular member at a
plurality of circumferentially spaced apart locations. /

19. The method of claim 18, wherein the plurality of circumferentially spaced apart
locations are positioned below the annular expansion cone:

20. The method of claim 17, wherein injecting a fl^idic material through the internal
passage of the tubular support member into an annular chamber above the annular
expansion cone to displace the annular expansion cone downwardly relative to the
tubular member to radially expand and plastically deform the tubular member
comprises: /

displacing an annular piston positioned within the annular chamber above the
annular expansion coner towards the annular expansion cone.

21 . The method of claim 20/wherein displacing an annular piston positioned within
the annular chamber above me annular expansion cone towards the annular expansion
cone comprises: /

exhausting fluidic materials displaced by the displacement of the annular piston
into the internal passage of the tubular support member.

22. The method of claim 20, wherein displacing an annular piston positioned within
the annular chamber above the annular expansion cone towards the annular expansion
cone cefmprises:

CjLhe^awwtei^ lon^Itu^In^^ o xpa nsfon-eefre: —

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"23: The method o f. c l aim 17 _^wher ^ inje cting a fluidicjr^

passage of the tubular support member into an annular chamber above the annular
expansion cone to displace the annular expansion cone downwardly relatiy^to the
tubular member to radially expand and plastically deform the tubular member
comprises: /

fludicly sealing off the internal passage of the tubular support member.

24. The method of claim 23, wherein injecting a fluidic material through the internal
passage of the tubular support member into an annular cjafamber above the annular
expansion cone to displace the annular expansion conp downwardly relative to the
tubular member to radially expand and plastically deform the tubular member further
comprises: /

preventing debris from entering the anni/ar chamber above the annular
expansion cone. /

25. The method of claim 17, whereir/exhausting fluidic materials out of an annular
chamber within the tubular member Izfelow the annular expansion cone through the
internal passage of the tubular supfport member that are displaced by the downward
displacement of the annular expansion cone comprises:

exhausting the fluidic/naterials through the internal passage of the tubular
support menrfber into an annulus between the tubular support member
and the preexisting structure.

26. The method4f claim 25, wherein exhausting the fluidic materials through the
internal passaged the tubular support member into an annulus between the tubular
support member and the preexisting structure comprises:

exhausting the fluidic materials through a plurality of radial passages defined by
/ the tubular support member into an annulus between the tubular support
C _ member and the preexistin g structure

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2Z ThernettroJof clairfT267iAHTeFeia ^xhausting thg jiw d i c mate r ia l s through ^

plurality of radial passages in the tubular support member into an annulus betyreen the
tubular support member and the preexisting structure comprises: /

exhausting the fluidic materials through a plurality of flow controbralves housed
within the tubular support member into an annulus between the tubular
support member and the preexisting structure /

28. The method of claim 17, wherein decoupling the tubular support member from
the tubular member comprises: /

pressurizing an annular chamber between the tubular support member and the
tubular member. /

29. The method of claim 28, wherein decoupling the tubular support member from
the tubular member further comprises: /

decoupling the tubular support member from the tubular member when the
operating pressure within the annular chamber between the tubular
support member and the/tubular member exceeds a predetermined
amount. /

30. The method of claim 2j9; wherein decoupling the tubular support member from
the tubular member when tne operating pressure within the annular chamber between
the tubular support menroer and the tubular member exceeds a predetermined amount
comprises: /

displacing sr retaining sleeve when the operating pressure within the annular
cjramber between the tubular support member and the tubular member
/exceeds a predetermined amount.

31^/The method of claim 30, wherein decoupling the tubular support member from
JfeKe tubulai iroemkef-wti e i i the operating prooouro within the annu l ar c hamber between

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. — the^ttbtjtef-stjpport memoer anfr-the-tuhular mpmbef-exceeds~a predetermine
further comprises:

displacing the tubular support member relative to the tubular member in Jtfie axial
direction.

-P

in

I3
p

I3

m

32. The method of claim 17, wherein decoupling the tubular suppqpf member from
the tubular member comprises:

displacing the tubular support member downwardly relatiy§ to the tubular
member; and

displacing the tubular support member upwardly restive to the tubular support
member.

33. The method of claim 32, wherein decouplii)^ the tubular support member from,
the tubular member further comprises:

displacing a retaining sleeve when the^tubular support member is displaced
downwardly relative to the tabular member.

34. The method of claim 32, whep6in decoupling the tubular support member from
the tubular member further comprises:

decoupling the tubular support member from the tubular member at a plurality of
circumferential spaced apart locations when the tubular support member
is displaced/lipwardly relative to the tubular member.

35. The method of claim 32, wherein decoupling the tubular support member from
the tubular member further comprises:

displacing the tubular support member downwardly relative to the tubular
member;

rotating the tubular support member relative to the tubular member; and
'displacing the tubular support member upwardly relative to the tubular support
member. »

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TFieTneffiod ofcfanrrlTTwhefe^ proce ss for coupli pg- t h e l ad i allv expand ecT
tubular member to the preexisting structure further comprises: /
lubricating the interface between the annular expansion cone and the tubtjlar
member. /

37. The method of claim 17, wherein the process for coupling the radially expanded
tubular member to the preexisting structure further comprises: /

injecting a hardenable fluidic sealing materials through th^nnternal passage of
the tubular support member and the tubular member into an annulus
between the tubular member and the preexisting structure.

38. The method of claim 17, wherein the process/or coupling the radially expanded
tubular member to the preexisting structure furthe/comprises:

maintaining the annular expansion cone/in a substantially stationary position

relative to the tubular memberprior to the initiation of the radial expansion
of the tubular member. /

39. The method of claim 38, wherein maintaining the annular expansion cone in a
substantially stationary position relative to the tubular member prior to the initiation of
the radial expansion of the tubular member comprises:

applying a longitudinal force to the annular expansion cone to maintain the
annular expansion cone in contact with the tubular member.

40. The method p\ claim 17, wherein the process for coupling the radially expanded
tubular member to the preexisting structure further comprises:

stopping the radial expansion and plastic deformation of the tubular member by
/fluidicly coupling the annular chamber above the annular expansion cone
^- to the int e rna l passage of tha-t uhulgr support member ,

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44i Th^ nnpthnd-ef-clai>n 40, wltefsio ^topping the radja Lexpaft&ten- and plastic/
deformation of the tubular member by fluidicly coupling the annular chamber ajrove the
annular expansion cone to the tubular support member further comprises: /

sensing the change in operating pressure of the injected fluidic material caused
by fluidicly coupling the annular chamber above the anr^jlar expansion
cone to the internal passage of the tubular support member.

42. The method of claim 17, wherein the tubular membej/fncludes:

one or more spaced apart external sealing memb^s for sealing the interface
between the tubular member and the preexisting structure; and

one or more spaced apart engagement rinas for engaging the preexisting
structure. /

43. The method of claim 42, wherein me process for coupling the radially expanded
tubular member to the preexisting structure further comprises:

preventing damage to the sealing members and the engagement rings during
movement of the tubular member within the preexisting structure.

44. The method of clainpr 17, wherein the preexisting structure comprises a wellbore
casing. /

45. The methocKof claim 17, wherein the preexisting structure comprises an
underground mpfeline.

46. The method of claim 17, wherein the preexisting structure comprises a structural
support

*7 A mPibnd-A^AAiipling * tubular mpmhpr tp R p reexisting structure, comprising :

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*ete a3ab l y c eopttng-the-ta^ to a 4ttbtrtarsupport membentefifimg-^

internal longitudinal passage at a plurality of circumferentially spaced /
apart locations; /

coupling an annular expansion cone for engaging the tubular member te> the
tubular support member; /

positioning the tubular member and the annular expansion cone Within the
preexisting structure using the tubular support member/
fludicly sealing off the internal passage of the tubulapsupport member;

injecting a fluidic material through the internal passage ofme tubular support
member into an annular chamber above the annular expansion cone to
displace the annular expansion cone downwardly relative to the tubular
member to radially expand and plasticall^aeform the tubular member;

displacing an annular piston positioned within/the annular chamber above the
annular expansion cone towards the'annular expansion cone;

exhausting fluidic materials displaced b/the displacement of the annular piston
into the internal passage of the4ubular support member;
the annular piston applying Lan axial force to the annular expansion cone;

exhausting fluidic materials outjzff an annular chamber within the tubular member
below the annular expansion cone through the tubular support member
that are displaced by the downward displacement of the annular
expansion cone; /

exhausting the fluidic/materials displaced by the annular expansion cone

through a pk/rality of flow control valves housed within the tubular support
member into an annulus between the tubular support member and the
preexisting structure;

stopping theradial expansion and plastic deformation of the tubular member by
flLudicly coupling the annular chamber above the annular expansion cone
to the internal passage of the tubular support member and sensing the
Lchang c in operat in g p i essu i e of the injected tluidic material caused by-"--

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— Fttttdtely- coupl i ng tho annb dacohaml^ cxpanc i on c rate

to the internal passage of the tubular support member; and /
decoupling the tubular support member from the tubular member. /

48. The method of claim 47, wherein decoupling the tubular support member from
the tubular member comprises: /

pressurizing an annular chamber between the tubular suppoiwiember and the
tubular member. /

49. The method of claim 48, wherein decoupling the tubular support member from
the tubular member further comprises: /

decoupling the tubular support member from the^tubular member when the
operating pressure within the annular onamber between the tubular
support member and the tubular member exceeds a predetermined
amount. /

50. The method of claim 49, wherein decoupling the tubular support member from
the tubular member when the operatina/pressure within the annular chamber between
the tubular support member and the tubular member exceeds a predetermined amount
comprises: /

displacing a retaining sleeve when the operating pressure within the annular
chamber between the tubular support member and the tubular member
exceeds a predetermined amount.

51. The method of daim 50, wherein decoupling the tubular support member from
the tubular member Wnen the operating pressure within the annular chamber between
the tubular support/member and the tubular member exceeds a predetermined amount
further comprises:

displacipKj the tubular support member relative to the tubular member in the axial
Mrection.

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--52: Tfr^methodrrhctaOT 4 8, wh eiBia-dacou pl i ng th eilTSOtar-strpp^^

the tubular member comprises:

displacing the tubular support member downwardly relative to the tubulai/
member; and

displacing the tubular support member upwardly relative to the tubyfar support
member.

53. The method of claim 52, wherein decoupling the tubular syjDport member from
the tubular member further comprises:

displacing a retaining sleeve when the tubular suppprt member is displaced
downwardly relative to the tubular membej;

54. The method of claim 52, wherein decoupling the tubular support member from
the tubular member further comprises:

decoupling the tubular support member from the tubular member at a plurality of
circumferentially spaced apan locations when the tubular support member
is displaced upwardly rel^mve to the tubular member.

55. The method of claim 52, wfierein decoupling the tubular support member from
the tubular member further co/nprises:

displacing the tubuterf support member downwardly relative to the tubular
member;

rotating the tufeTular support member relative to the tubular member; and
displacing tjae tubular support member upwardly relative to the tubular support
member.

56. The rriethod of claim 47, wherein the process for coupling the radially expanded
tubular member to the preexisting structure further comprises:

lubricating the interface between the annular expansion cone and the tubular
-member:

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SFh ThB^rtetfio^of claim 47, wh^retrrthe-pfOGes^ the rad i a ll y oxpan c

tubular member to the preexisting structure further comprises:

injecting a hardenable fluidic sealing materials through the tubular suppc

member and the tubular member into an annulus between the/tubular

member and the preexisting structure.

58. The method of claim 47, wherein the process for coupling th^radially expanded
tubular member to the preexisting structure further comprises:

maintaining the annular expansion cone in a substantia^ stationary position

relative to the tubular member prior to the initiation of the radial expansion
of the tubular member.

59. The method of claim 58, wherein maintaining / the annular expansion cone in a
substantially stationary position relative to the tubular member prior to the initiation of
the radial expansion of the tubular member comprises:

applying a longitudinal force to the annular expansion cone to maintain the
annular expansion cone in/contact with the tubular member.

60. The method of claim 47, wherein the tubular member includes:
one or more spaced apapt external sealing members for sealing the interface

between the tubular member and the preexisting structure; and
one or more space^apart engagement rings for engaging the preexisting
structure.

61 . The method/6f claim 60, wherein the process for coupling the radially expanded
tubular member/to the preexisting structure further comprises:

preventing damage to the sealing members and the engagement rings during
^movement ^i4he-ttrta tJ l ^r nmmhm wilhin l l m preexisting stroctor er —

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-62, Thglnethod of claim 4/, wherein the pree^stingltmctui^comprises a wellborfe/

casing. /

63. The method of claim 47, wherein the preexisting structure comprises anr
underground pipeline. /

64. The method of claim 47, wherein the preexisting structure conwises a structural
support. /

65. The method of claim 2, wherein the expansion cone comprises an annular
expansion cone; and wherein positioning the support member, the annular expansion
cone, and the tubular member within the preexisting structure comprises:

releasably coupling the tubular member to a hroular support member defining an
internal longitudinal passage at a plurality of circumferentially spaced
apart locations positioned below We expansion cone; and

coupling the annular expansion cone to the tubular support member.

66. The method of claim 2, wherein injecting the first quantity of the fluidic material
into the preexisting structure below the expansion cone comprises:

injecting a hardenable fluidic^ealing material through the internal passage of the
tubular support member and the tubular member into an annulus between
the preexisting structure and the tubular member.

67. The method of clairof 2, wherein the expansion cone comprises an annular
expansion cone; and wherein injecting the second fluidic material through the internal
passage of the tubulat/support member into the preexisting structure above the annular
expansion cone comprises:

fludioly sealing off the internal passage of the tubular support member;
injecting the second fluidic material through the internal passage of the
^ — tubulan sup port m e mbe r i n t o an annu l ar chambe r above t hfl - — *

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PATENT

"-^rrfttrfctf^-expgTTSio n cono te disp l aG e^t he annu lar expansion cone^
downwardly relative to the tubular member to radially expand/and
plastically deform the tubular member; /

exhausting fluidic materials out of an annular chamber within ttie tubular
member below the annular expansion cone through tne tubular
support member that are displaced by the downward displacement
of the annular expansion cone; /

exhausting the fluidic materials displaced by the awiular expansion cone
through a plurality of flow control valves iroused within the tubular
support member into an annulus between the tubular support
member and the preexisting structure; and

stopping the radial expansion and plastic deformation of the tubular
member by fluidicly couplinq^ne annular chamber above the
annular expansion cone tp the internal passage of the tubular
support member and sensing the change in operating pressure of
the injected fluidic material caused by fluidicly coupling the annular
chamber above tHe annular expansion cone to the internal passage
of the tubular^upport member.

68. The method of claim Z wherein the expansion cone comprises an annular
expansion cone; and wherein the process for coupling the radially expanded tubular
member to the preexisting structure further comprises:

lubricating th/e interface between the annular expansion cone and the tubular
member.

69. Th^r method of claim 2, wherein the expansion cone comprises an annular
expansion cone; and wherein the process for coupling the radially expanded tubular
ro ^mher tn the pr o oxist i ng structure furth o r comprises:

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Attorney Docket No. 25791 .85 PATENT

jnaintaijiing the annular gyp^ ns io n n o n e in a nuhnt n nt i n l ly st ^ t ' ^"^^ p^^ ntt^p

relative to the tubular member prior to the initiation of the radial expansion
of the tubular member.

70. The method of claim 69, wherein maintaining the annular expansion cone in a
substantially stationary position relative to the tubular member prior^to the initiation of
the radial expansion of the tubular member comprises:

applying a longitudinal force to the annular expansion c6ne to maintain the
annular expansion cone in contact with the tubular member.

if /

13 71 . The method of claim 2, wherein the preexisting structure comprises a wellbore

13

,S casing.

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ffi 72. The method of claim 2, wherein the pj^existing structure comprises an
underground pipeline.

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0 73. The method of claim 2, wher^tfi the preexisting structure comprises a structural
^ support.

liy

74. The method of claim 1/>, wherein decoupling the support member from the
tubular member comprises

pressurizing an anriular chamber defined between the support member and the
tubular member.

75. The methocr of claim 74, wherein decoupling the support member from the
tubular member/further comprises:

decoupling the support member from the tubular member when the operating

pressure within the annular chamber defined between the tubular support
membera nd the tubu l a r m e mber e xc e edc a prodot o rmined a mount. *

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Attorney Docket No. 25791.85

PATENT

— — "ThgTrrettT5g"gt x l a i m 70, whoroin d e coupl i ng tho sup p oi rmemberfrem
tubular member when the operating pressure within the annular chamber defied
between the tubular support member and the tubular member exceeds a [Redetermined
amount comprises:

displacing a retaining sleeve when the operating pressure witftm the annular
chamber defined between the support member ancf/fhe tubular member
exceeds a predetermined amount.

77. The method of claim 76, wherein decoupling the support member from the
tubular member when the operating pressure within me annular chamber defined

p between the support member and the tubular merpoer exceeds a predetermined

O amount further comprises:

iy displacing the support member relativ^to the tubular member in the axial

j£ direction.

S3

78. The method of claim 15, wherein decoupling the support member from the
tubular member comprises:

v d displacing the support member downwardly relative to the tubular member; and

u /

IU displacing the support member upwardly relative to the tubular member.

79. The method of claim 78, wherein decoupling the support member from the
tubular member further Comprises:

displacing a retaining sleeve when the support member is displaced downwardly
relative^ to the tubular member.

80. The method of claim 78, wherein decoupling the support member from the
tubular member further comprises:

decoupling the support member from the tubular member at a plurality of
circumferentially spaced apart locations when the support member is
lisplace d upward l y re tative-t o the tub u l a r m e mber -:

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Attorney Docket No. 25791.85

PATENT

frt: The-roe thod of cl ai rc ^^&T-wb ftre i n dec o upling th es upport m embej^fremiht

tubular member further comprises:

displacing the support member downwardly relative to the tubular rp6mber;
rotating the support member relative to the tubular member; anc
displacing the support member upwardly relative to the tubular support member.

T52T The method of claim 5, fuftRer comprising:

removing the coupling elements from the pairs of coupling slots by pressurizing
an annular chamber defined between the/first and second member.

83. The method of claim 82, wherein removino / the coupling elements from the pairs
of coupling slots by pressurizing an annular chamber defined between the first and
second member comprises: /

removing the coupling elerfiente frefm the D^ifs of coupling slots when the

operating pressure withi^4l=^ruy(jlar chamber defined between the first
and second member exceeds^ predetermined amount.

84. The method of claim 8yrettooving the coupling elements from the pairs of
coupling slots when the operating pressure within the annular chamber defined
between the first and second member exceeds a predetermined amount comprises:

displacing a retaining sleeve when the operating pressure within the annular
chamber defined between the first and second member exceeds a
predetermined amount.

85. The method of claim 84, wherein removing the coupling elements from the pairs
of coupling aflots when the operating pressure within the annular chamber defined
between tbfe first and second member exceeds a predetermined amount comprises:

displacing the first member relative to the second member in the axial direction.

86. Zjbe-fflethod~of claiirrSrfaftheu ^^

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Attorney Docket No. 25791.85

PATENT

— pemoviftg-t^e coupl i ng ele m e nt s tonLtbe- p airo of cou pli n g c lots by d isp la c if
first member downwardly relative to the second member and then
displacing the first member upwardly relative to the second memb*

87. The method of claim 86, wherein decoupling the first member from jKe second
member further comprises:

displacing a retaining sleeve when the first member is displaced downwardly
relative to the second member.

88. The method of claim 5, further comprising decouplingine first member from the
second member by decoupling the first member from the second member at a plurality
of circumferentially spaced apart locations by displacinjg^the first member upwardly
relative to the second member.

89. The method of claim 5, further qornprj
second member by displacing the first

scowling the first member from the

lember downwardly relative to the second
member, rotating the first member relattWo the second member, and displacing the
first member upwardly relative to the second memoer.

90. A method of coupling a first member to a second member, comprising:
forming a first set of coupling slots in the first member;
forming a second set of Coupling slots in the second member;
aligning the first and second pairs of coupling slots;
inserting coupling elements into each of the pairs of coupling slots; and
removing the coupling elements from the pairs of coupling slots by:

pressurizing an annular chamber defined between the first and second
fember;

remoyfng the coupling elements from the pairs of coupling slots when the
operating pressure within the annular chamber defined between
firct -anH cprnnH marnhpr PYr.pq f fc a predetermined amount;

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Attorney Docket No. 25791.85

PATENT

displacing a retaining~steere^lren/th e- operating th e
annular chamber definepl oeb/j^girtfie first and second member
exceeds a predetermirj©«^mount; and

displacing the first meniber relative to the second member in the axial

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